Suzuki stage 2Make your own adaptor plateWill that big 9" motor fit?Coupler and adaptor plateMotor in car
OwnerPaul H
LocationAdelaide, South Australia Australia map
Email email image
Vehicle1992 Suzuki Swift GTi
I picked the Swift as it is very light (It weighed 880kg with a full tank of fuel on the local weighbridge). I am building the EV swift to see how it performs. If I am happy with it I will convert a Lotus Elise and build my own "mini Tesla". If the GM EV-1 was available, I would buy one tomorrow.
MotorAdvanced DC FB1-4001 single shaft 9 Compound Wound DC
Great reliable motor that has plenty of power to push the light weight swift along using 144 volts! The standard GTi has 100HP at 6200RPM. The FB1 motor is capable of instant 100HP at stall!
Drivetrain5 speed manual original gearbox (clutchless)
ControllerCafe Electric Zilla 1K
Zilla = performance, so for me it was an easy choice. I'm on the waiting list.....Expected delivery is Nov 2009.
Batteries45 Skyenergy Lithium 120Ah, 3.40 Volt, Lithium-Polymer
They are light weight AND high power. Ideal for long-term use. They are the most expensive compnents, but the batteries are the "heart" of he system.
System Voltage144 Volts
ChargerZivan NG3
Great charger. Ideal for LiPo4 batteries.
Heater12v hairdryer (required to meet design rules here in Australia). I don't really need a heater though!
DC/DC ConverterIota DLS-55
100-180v DC in - 13.4V out (55A)
InstrumentationStandard instrumentation (speedo etc) with AMP& VOLT meters added.
Top Speed90 MPH (144 KPH)
Maximum speed should be 150kph but the speed limit in Australia is 110kph so the top speed is more than required. My commute is usually on roads with a 50kph or 60kph speed limit.
AccelerationIt will have very "lively" performance for normal road use as the power to weight ratio is very good. 0-80kph (50mph) should be achieved in approx 7 seconds.
Range60 Miles (96 Kilometers)
60 miles or 100kms will be more than enough for my 20km (12.5mile) trip to work and back. This is a commuter vehicle for the city. We will use my wifes car for any long distance trips.
Watt Hours/MileWill advise when I know
Seating Capacity4 people
Curb Weight2,266 Pounds (1,030 Kilograms)
It will be around 1030kg after the conversion.
Tires195 x 60 x 14 with alloy wheels for weight reduction.
Conversion TimeThis car will be finished within 4 months and I will update this site regularly.
Conversion Costapprox $20,000 (car was $3,000)
I could have done it cheaper but I really wanted to buy good quality components that will give me lively performance so that I can test them in the Suzuki GTi first. I want an electric car that drives almost as good as GM's EV-1. If I can achieve that, then to me it will be a huge success!

Sept 2009: ICE out, fuel tank out,exhaust off, sorted out existing wiring, shocks & driveshafts out.

Oct 2009: Cleaned up engine bay & re-painted, made motor adaptor plate, ordered FB1 motor and Zilla controller + other bits, new driveshafts have arrived (Ebay $220 pair - NEW!!).

29/10/09 Motor has arrived. I'll be making the motor to gearbox coupler this weekend so that I can get the motor in and test it with 12v.

2/11/09: I had to make an extra spacer to go between the adaptor plate and the motor (8mm) as the coupler was slightly too long! Ordered 45xSky 120Ah Litium batteries and a LOT of other EV parts from EV Works. They are due to arrive in the next 2 weeks! This project is moving along quicker than I thought!

14/11/09: The electric motor and gearbox are now joined and they fit together perfectly! I turned the motor and the driveshafts moved, so its definitely connected!

15/11/09: I have installed the electric motor and gearbox into the car. I made an exact "cardboard" engine mount for the left side of the motor which I'm getting made from steel this week so that I can install it next weekend. Then I can remove engine hoist and trolley jack from the motor. The batteries and other EV parts will arrive any day now.

code by jerry